Manual fuel valve option

The 81 KZ650-H1 CSR bolt-hole spacing is 34mm. The fuel valve linked below may work on a number of 80s models. If the 83 CSR spacing is 34mm, It may also work on the later Police bikes, since the the H3 CSR petcock supersedes to the 2005 P-24 part.

Note: this fuel valve may be a copy of a Yamaha part. see followup in next reply.
CSR650 CSR750 CSR 650 750 TWIN PETCOCK FUEL VALVE .
seller is brownfamilyracing

The part above might be an aftermarket Yamaha manual fuel valve.
Someone on another forum put a new Yammy Raptor fuel cock on his Zephyr 550.
34mm bolt-hole spacing?

Yamaha fuel cock: 5LP-24500-01-00 (~$20 at ronayers.com).

5LP-24500-00-00 looks to be almost identical (this one is superseded by the -01-00 unit).
There may be other Yamaha fuel valves.

Edit: Here's another one.

Listed for a Suzuki DR 650. others are available.
Suzuki DR 650 fuel valve

Edit: just cross-referencing a topic.
Manual petcock on kz750 csr?

Really? For that price, if I can confirm it would fit my KZ, I'd get one in case mine fails- I modified mine from vacuum to manual- milled the top off (inside tank) so its either on..or off- rode around with a gastank to see just how far I could get on a tank of gas, so a reserve isnt suited to my rig as long as the gauge gets 12v and the speedometer keep working.

nice find!

that last link isn't working for me- I'll try again after rebooting router.

34mm bolt hole spacing

KZ440 KZ550 KZ 440 550 FUEL TANK SHUTOFF SWITCH VALVE
seller is imotorpartsusa. manualfuelvalve optionz

martin_csr wrote: Edit: fixed the link.... sorry about that.

If the spacing on your 81 1100 is 34mm, then it should work. I've been riding around w a disabled vacuum petcock for a few weeks, but now even it is leaking. If a new diaphragm kit doesn't work (already purchased, doh), then I'm switching to a manual.

PS: a clear plastic Tropicana orange juice jug is handy for collecting the fuel when the bike is parked in the garage... saves the fuel for reuse & cuts way down on the gasoline fumes.

I modified mine. I thought I posted pics/how to here. I just searched, guess not.
Basically, I stared at it till I figured out what had to be done, filled the holes with that two part gas tank repair, the lever you turn I modified. It was far more simpler than I thought when I started. It doesn't leak a drop. I left a nearly full tank, off the bike, sitting in the sun while I did something, I could smell gas around the cap vent, and my modded valve was bone dry.
After done, I took a file and flat filed where the filters were. Had to make a gasket that lined up with the holes, all very simple, total cost was bout 5.00 and an hour.

I used the vacuum petcock as a manual fuel valve for a couple of weeks.... not a good permanent solution, since there is no reserve --- PRI functioned as the fuel supply & ON/RES stopped the fuel flow.

argh...if I didn't fill my tank last night, I'd go pull it and take photos!
If you eyeball it, you'll see where the reserve feeds to the fuel "out".
Plug the vacuum line out with that tank repair. You look at the lever that controls res/fuel etc you'll need to remove a tab allowing it to move past its stop. Like I said, 5.00 and mine hasn't leaked a drop in 5 months. Hmm, seems I didn't upload to an offsite, but did it here, still cant find the photos..dangit.


www.kzrider.com/media/kunena/attachments/22743/rsz_picture.jpg

Vacuum petcock. 44mm bolt hole spacing??? The 1983 KZ650-CSR petcock is part #51023-1039 & it supersedes to #51023-1375 which is an Active part & was used on the 2002/03/05 Police bikes. Someone over at the KZ650.info site put a new one on his 78 650B model --- I believe the bolt hole spacing is 44mm on the 70s models, so I guess the -1375 part is 44mm.

Also, a vac petcock from a ZG1000 Concours may be a viable option as well.
51023-1388 --- 2000-06
51023-1330 --- 1986-99

Conversion KIt for converting a vacuum petcock to a manual fuel valve.
Here's something I just stumbled across. This conversion kit might work on many KZ models as the Concours has the same diaphragm cover assy & tap lever o-ring. It looks kinda nifty, but I haven't taken the time to compare the Concours part to the KZ.

MurphsKits.com - ZG1000 Concours Manual Petcock Conversion Kit

MurphsKits.com - ZG1000 Concours Manual Petcock Conversion Kit - Installation pdf w good photos

martin_csr wrote: Conversion KIt for converting a vacuum petcock to a manual fuel valve.
Here's something I just stumbled across. This conversion kit might work on many KZ models as the Concours has the same diaphragm cover assy & tap lever o-ring. It looks kinda nifty, but I haven't taken the time to compare the Concours part to the KZ.

MurphsKits.com - ZG1000 Concours Manual Petcock Conversion Kit

MurphsKits.com - ZG1000 Concours Manual Petcock Conversion Kit - Installation pdf w good photos

Martin, I would love to try out this kit if I thought it would fit my bike. That would be better than my prime/on and on and reserve /off setup I have now.

Just clarifying the topic post as I had assumed that the 82-83 csr petcocks had the same spacing as the 81. doh.
The bolt hole spacing of the aftermarket fuel valve is listed as 34mm. same as the 81 csr.
The 82-83 650-csr bolt hole spacing should be 44mm & the 82-2005 police bikes should also be 44mm.

The Yamaha raptor fuel valve should be 34mm. oem & made in Japan. ~$30.
there are several different raptor fuel valves.

Stuff to check when getting a non-stock fuel valve. extension of fuel valve body below the tank. --- some extend down, some are tucked up close to the tank. pickup tube length. fuel port O.D. country of origin --- Japan, Taiwan, china.